Insert for dispensing a compressed gas product, system with such an insert, and method of dispensing a compressed gas product

ABSTRACT

An insert, a system, and a method are provided for dispensing a compressed gas product. The insert includes a swirl chamber, inlet ports to the swirl chamber, and an outlet orifice. The insert has specifically configured parameters relating to the diameter of the swirl chamber, the diameter of the outlet orifice, the length of the outlet orifice, and the depth of the swirl chamber. The insert, system, and method can provide a dispensed compressed gas product with a remarkably constant flow rate and with a remarkably constant particle size.

The application claims priority to U.S. Provisional Application No.61/457,925, filed Jul. 8, 2011.

BACKGROUND

1. Field of the Invention

Our invention relates to an insert for dispensing a compressed gasproduct, a system that includes such an insert, and a method ofdispensing a compressed gas product. More generally, our inventionrelates to apparatuses, systems, and methods for dispensing compressedgas products with a relatively constant flow rate and with a relativelyconstant particle size.

2. Related Art

In general, aerosol dispensers provide low cost, easy to use methods ofdispensing products, typically, as an airborne mist. Thus, aerosoldispensers have been commonly used to dispense personal, household,industrial, and medical products. The airborne mist provided by anaerosol dispenser itself may provide a desired effect, as is the casewith air freshening fragrances. Alternatively, the mist may be used toform a thin coating on surfaces, such as with furniture polishes.

Typically, aerosol dispensing systems include a container that holds aproduct with liquid and gas parts. Examples of liquid compositionsincluded in aerosol systems are air and fabric fresheners, soaps,insecticides, paints, deodorants, disinfectants, and the like. The gasincluded with the liquid product acts as a propellant to discharge theliquid product from the container. The propellant pressurizes thecontainer holding the liquid composition, and provides 00050.129200 aforce to expel the liquid composition from the container when a useractuates the aerosol dispenser by pressing an actuator button ortrigger.

There are two main types of propellants used in aerosol systems: (1)liquefied gas propellants, such as hydrocarbon and hydrofluorocarbon(HFC) propellants, and (2) compressed gas propellants, such as carbondioxide and nitrogen. In the past, chlorofluorocarbon propellants (CFCs)were used as propellants in aerosol systems. The use of CFCs, however,has essentially been phased out due to the potentially harmful effectsof CFCs on the environment.

In an aerosol system that uses a liquefied petroleum gas-type propellant(LPG), the container is loaded with liquid composition and LPGpropellant to a pressure approximately equal to the vapor pressure ofthe LPG. After being filled, the container has a certain amount of spacethat is not occupied by liquid. This space is referred to as theheadspace. Since the container is pressurized to approximately the vaporpressure of the LPG propellant, some of the LPG is dissolved oremulsified in the liquid product. The remainder of the LPG remains inthe vapor phase and fills the headspace. As the product is dispensed,the pressure in the container remains approximately constant becauseliquid LPG moves from the liquid to the vapor in the headspace, therebyreplenishing discharged LPG propellant vapor.

In contrast, compressed gas propellants in aerosol systems largelyremain in the vapor phase. That is, only a relatively small portion of acompressed gas propellant is contained in the liquid composition. Hence,a “compressed gas product” includes a liquid composition and acompressed gas propellant. As a result, the pressure within a compressedgas aerosol dispenser assembly decreases as the product is dispensed.While this aspect of using compressed gas propellants is, in some ways,disadvantageous, the use of compressed gas propellants has gained favoras compressed gas propellants do not usually contain volatile organiccompounds (VOCs). On the other hand, LPGs are considered to be VOCs,thereby making their use subject to various regulations.

From a consumer satisfaction standpoint, an important aspect of anaerosol system is that the system provides a consistent fragranceexperience provided by a consistent flow rate and a consistent particlesize. A consistent flow rate and a consistent particle size ensures thata relatively consistent effect is achieved as the product is dispensedfrom the container. For example, in the case of air freshening products,the fragrance experience is a function of the amount of fragrance in theair, which in turn is related to both the flow rate and particle size ofproduct dispensed by the related system. Thus, it is important that theflow rate and particle size of product that is dispensed when thecontainer is relatively full be as close as possible to the flow rateand particle size of product that is dispensed when the container isrelatively empty so that the user can achieve the same levels of airfreshening with equal lengths of application, regardless of the amountof product remaining in the container.

Ideally, in an aerosol system configured to dispense an air freshener,the system dispenses a product with a flow rate and a particle size suchthat a sufficient amount of fragrance experience is achieved soon afterthe dispensing, but also such that there is longevity in the fragranceexperience. The higher the flow rate of product from the system, themore fragrance that will be available with a given length ofapplication. Too high of flow rate, however, may lead to an overwhelmingfragrance experience. With respect to particle size, larger particlesprovide a smaller total surface area for evaporation of the fragrance ascompared to an equivalent volume of smaller particles. The smallersurface area for evaporation of fragrance in larger particles providesfor less of an initial fragrance experience compared to an equivalentvolume of smaller particles. However, the smaller surface area forevaporation of fragrance in larger particles provides for a longerfragrance experience compared to an equivalent volume of smallerparticles, i.e., the fragrance evaporates more slowly from the largerparticles. Still other factors are taken into account when consideringthe particle size for an air freshener. Smaller particles may be moreeasily carried away with air flow, which also reduces the longevity ofthe fragrance experience. On the other hand, there is a greater tendencyfor larger particles to fall out of the air and onto surfaces. Such fallout behavior of larger particles is often undesirable because of theresulting accumulation on a surface.

Ideally, an aerosol system is configured to provide a flow rate andparticle size that balances these considerations. That is, the aerosolsystem provides a flow rate and particle size such that a sufficientamount of fragrance is available quickly after dispensing the product,with the product particle sizes providing longevity to the fragranceexperience, but not so large to present substantial fall out. Withcompressed gas propellants, however, there is a tendency for the sprayrate to decrease as the product is dispensed from a container. Further,there is a tendency for the particle size to increase as the product isdispensed from the container. In prior art dispensing systems, the flowrate may decrease by more than 40% as the product in the container isused up. In the same prior art systems, the particle size may increaseby more than 50% as the product in the container is used up.Accordingly, the desired effects of the dispensed product achieved byhaving a consistent flow rate and a consistent particle size are notfound in prior art compressed gas aerosol systems. Further, even if theinitial flow rate and initial particle size can provide an air freshenerwith a good fragrance experience, the changes in the flow rate andparticle size may degrade the fragrance experience.

SUMMARY OF THE INVENTION

According to one aspect of the invention, an insert is provided for usewith an assembly to dispense a compressed gas product from a container.The insert comprises a swirl chamber having a diameter Ds and a depthLs, at least one inlet port opening to the swirl chamber, and an outletorifice having a diameter do and a length lo. The insert is configuredsuch that Ds/do is about 3.0 to about 3.5, lo/do is about 0.4 to about0.6, and Ls/Ds is about 0.3 to about 1.0.

Another aspect of the invention is a method of dispensing a compressedgas product from a container and a dispenser assembly that includes aninsert with a swirl chamber. The method comprises providing a product inthe container such that the pressure inside the container is less thanabout 157 psi. The product is dispensed from the container through theinsert such that the flow rate of product out of the insert when thecontainer is about 13% full of product is at least about 65% that of theinitial flow rate of product when the container is 100% full of product.

Yet another aspect of the invention is a method of dispensing acompressed gas product from a container that includes an insert with aswirl chamber. The method comprises providing a product in the containersuch that the pressure inside the container is less than about 157 psi,and dispensing the product from the container through the insert suchthat the particle size increases by less than about 40% as the amount ofproduct in the container drops to 13% of the initial amount of productin the container.

Another aspect of the invention is related to a method of minimizing achange in flow rate of a compressed gas product and minimizing anincrease in particle size of the compressed gas product dispensed from acontainer through a dispenser assembly that includes an insert. Theinsert has (i) a swirl chamber with a diameter Ds and a length Ls, (ii)at least one inlet port opening to the swirl chamber, the at least oneinlet port having a cross-sectional area Ap, and (iii) an outlet orificehaving a diameter do and a length lo. The method comprises adjusting theratio Ds/do to be in the range of about 3.0 to about 3.5, adjusting theratio lo/do to be in the range of about 0.4 to about 0.6, adjusting theratio Ls/Ds to be in the range of about 0.3 to about 1.0, and adjustingthe ratio Ap/(Ds·do) to in the range of about 0.3 to about 0.9.

According to a further aspect of the invention, a system is provided fordispensing a compressed gas product. The system comprises a containerfor containing a volume of compressed gas product, and a compressed gasproduct inside the container, with the compressed gas product includinga compressed gas component and a liquid component. The compressed gasproduct dispensed from the container has a flow rate of (i) at leastabout 2.0 g/s during an initial ten second dispensing period from thecontainer, and (ii) at least about 1.3 g/s during a ten seconddispensing period when the container has about 13% of the initial amountof compressed gas product remaining in the container.

According to another aspect of the invention, a system is provided fordispensing a compressed gas product. The system comprises a containerfor containing a volume of compressed gas product, with the compressedgas product including a compressed gas component and a liquid component.The compressed gas product dispensed from the container has a flow rateof (i) at least about 2.0 g/s during an initial ten second dispensingperiod from the container, (ii) at least about 1.7 g/s during a tensecond dispensing period when the container has about 66% of the initialamount of compressed product remaining, (iii) at least about 1.4 g/sduring a ten second dispensing period when the container has about 33%of the initial amount of compressed product remaining, and (iv) at leastabout 1.3 g/s during a ten second dispensing period when the containerhas about 13% of the initial amount of the compressed gas productremaining

A different aspect of the invention is directed to a system fordispensing a compressed gas product. The system comprises a container,and a compressed gas product provided inside the container, with thecompressed gas product including a compressed gas component and a liquidcomponent. The system is configured to dispense the compressed gasproduct with a flow rate of such that a flow rate of compressed gasproduct when the system is about 13% full of product is at least about65% that of an initial flow rate of product when the system is 100% fullof product. The system is also configured to dispense the compressed gasproduct such that the particle size increases by less than about 40% asthe amount of product in the container drops to 13% of the initialamount of product in the container.

In other aspects of the invention, a method is provided for minimizing achange in flow rate of a compressed gas product and minimizing anincrease in particle size of the compressed gas product dispensed from acontainer through an insert provided to a dispenser assembly associatedwith the container. The insert has (i) a swirl chamber with a diameterDs and a length Ls, (ii) at least one inlet port opening to the swirlchamber, the at least one inlet port having a cross-sectional area Ap,and (iii) an outlet orifice having a diameter do and a length lo. Themethod comprises adjusting the ratio Ds/do, adjusting the ratio lo/do,adjusting the ratio Ls/Ds, and adjusting the ratio Ap/(Ds·do). A sprayrate during an initial sixty second dispensing of the compressed gasproduct through the insert is at least about 1.7 g/s.

Another aspect of the invention is directed to a method of maintaining aspray rate of compressed gas product. The method comprises providing thecompressed gas product inside a container such that the pressure insidethe container is less than about 157 psi, and dispensing the compressedgas product from the container. The compressed gas product has a flowrate of at least about 1.7 g/s during an initial sixty second dispensingfrom the container, and the spray rate decreases by less than about 0.7g/s as the compressed gas product is discharged from a full container toa point when the container has about 13% of the compressed gas productremaining

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an aerosol dispenser having aninsert according to the invention.

FIG. 2 is a cross-sectional view of an insert according to theinvention.

FIG. 3 is a cross-sectional view of the swirl chamber of the insertshown in FIG. 2.

FIG. 4 is a rear elevation view of the insert shown in FIG. 2.

FIG. 5 is a front elevation view of the insert shown in FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

Our invention is related to an insert for dispensing a compressed gasproduct, a system that includes such an insert, and a method ofdispensing a compressed gas product. As will be described below, theinsert can be used with an aerosol dispenser assembly to dispense acompressed gas product from a container in a manner that maintains arelatively constant flow rate and a relatively constant particle size.Similarly, a method according to the invention provides steps fordispensing a compressed gas product with a relatively constant flow rateand a relatively constant particle size.

FIG. 1 depicts an aerosol dispenser assembly 10 that includes an insert21 according to the invention. The aerosol dispenser assembly 10includes a container 11 covered by a mounting cup 12. A mounting gasket(not shown) may be disposed between an upper rim of the container 11 andthe underside of the mounting cup 12. A valve assembly 13 is used toselectively release the contents from the container 11 to theatmosphere. The valve assembly 13 comprises a valve body 14 and a valvestem 15. The valve stem 15 includes a lower end 16 that extends througha return spring 17. An actuator body 18 is mounted on top of the valvestem 15 and defines a primary passageway 19. The actuator body 18 isalso connected to the nozzle insert 21 that defines an exit orificeshown generally at 22. The insert 21 will be discussed in greater detailbelow.

An upper rim 23 of the valve body 14 is affixed to the underside of themounting cup 12 by a friction fit and the valve stem 15 extends throughthe mounting cup 12. The actuator body 18 is frictionally fitted ontothe upwardly extending portion 24 of the valve stem 15. The lower end 25of the valve body 14 is connected to a dip tube 26. Gaskets may or maynot be provided between the valve body 14 and the mounting cup 12, andbetween the valve stem 15 and the mounting cup 12, depending upon thematerials used for each component. Suitable materials that will permit agasket-less construction will be apparent to those skilled in the art.Similarly, gaskets or seals are typically not required between theactuator body 18 and the upper portion 24 of the valve stem 15. Whilethe dispenser assembly 10 of FIG. 1 employs a vertical action-typeactuator body or cap 18, other actuator cap designs may be used, such asan actuator button with an integral over cap, a trigger actuatedassembly, a tilt action-type actuator cap, or other designs.

In operation, when the actuator body 18 is depressed, the valve stem 15moves downward, thereby allowing pressurized liquid product to bepropelled upward through the dip tube 26 and the lower portion 25 of thevalve body 14 by the propellant. From the valve body 14, the product ispropelled past the lower end 16 of the valve stem 14 through the channel26 and through the stem orifice(s) 27, out the passageway 28 of thevalve stem and into the primary passageway 19 of the actuator body 18.In some embodiments, two valve stem orifices 27 are employed, as isshown in FIG. 1, although a single valve stem orifice 27 or more thantwo valve stem orifices 27 may be used. Multiple valve stem orifices 27may provide greater flow and superior mixing of the compressed gasproduct.

It should be noted that while specific features and a configuration fora system for providing a compressed gas product are exemplified in thedispenser assembly 10, our invention is not limited to such features andconfiguration. Indeed, as will be appreciated by those skilled in theart, a wide variety of dispenser assemblies could be used with theinventive insert, systems, and methods described herein.

FIGS. 2-5 show an example embodiment of an insert 21 according to theinvention. The insert 21 includes a sidewall 32 that defines asubstantially circular shape, and an endwall 29 that includes an outletorifice 22. It should be noted, however, the shape of the sidewall couldbe varied such that the insert 21 includes, for example, a plurality ofsidewalls defining a rectangular shape or any other polygonal shape. Ofcourse, the corresponding slot in the actuator body of the dispenserassembly that receives the insert 21 will be shaped to correspond to theshape of the sidewall 29.

The insert 21 includes a plurality of inlet ports 30 that lead to aswirl chamber 31. The swirl chamber 31 is in fluid communication withthe outlet orifice 22. Thus, the insert 21 provides a fluid pathway fromthe inlet ports 30 to the swirl chamber 31, and then out of the insert21 through the outlet orifice 22. Thus, a compressed gas productcontained in a system including a container and dispenser assembly, suchas those described above, can be dispensed through the fluid pathway inthe insert 21.

The configuration of the swirl chamber 31 and the tangentiallypositioned inlet ports 30 creates a swirling motion to the liquid in thechamber 31. As a result, a core of air extends from the rear of theswirl chamber 31 to the outlet orifice 22. Thus, the product dispensedfrom the outlet orifice 22 is released as an annular sheet, whichspreads radially outward to form a hollow conical spray. It should benoted that although four inlet ports 30 are shown in the depictedembodiment, the number of inlet ports 30 can be any number, includingonly a single inlet port. The number of inlet ports 30 will depend onfactors such as, for example, the size of the corresponding system, thedesired shape of the system, etc.

Certain parameters of the insert 21 are shown in FIGS. 2 and 3. One suchparameter is the “diameter” Ds of the swirl chamber 31. As is apparentfrom FIGS. 3-4, the swirl chamber 31 has a substantially square shape.In view of the substantially square shape, the diameter Ds representsthe maximum diameter of a circle that can be contained in the swirlchamber 31. In alterative embodiments, however, the swirl chamber 31 canhave a circular shape, wherein the diameter Ds is the actual diameter ofthe chamber.

Other parameters of the swirl chamber 31 and outlet orifice 22 are shownin FIG. 2. One such parameter is the depth of the swirl chamber Ls. Inthis case, the depth Ls is the same size as the depth of the inlet ports30 provided to the swirl chamber 31. In other embodiments, however, thedepth of the swirl chamber 31 may be different from the depths of theinlet ports 30. Parameters of the outlet orifice 22 include a diameterdo, and a length lo that the outlet orifice extends from the swirlchamber 31 to the final outlet of insert 21.

The inlet ports 30 leading to the swirl chamber 31 are substantiallyrectangular in shape, and therefore have a length and depth (or width).As such, the inlet ports 30 provide a total cross-sectional area Apopening to the swirl chamber 31. As noted above, that the number ofinlet ports 25 provided to the swirl chamber 31 can be varied. Alongthese lines, the shape and angle of the ports 30 with respect to theswirl chamber 31 can also be varied. It should be noted, however, thatregardless of aspects such as the number, shape, and positioning of theinlet ports 30, differently configured inlet ports still can provide theequivalent cross-sectional areas Ap.

Prior art nozzle inserts have included swirl chambers, inlet ports, andexit orifices. And attempts have been made in the prior art to adjustsome of the parameters of these structures in order to achieve variouseffects in dispensing compressed gas products. For example, U.S. PatentApplication Pub. No. 2009/0020621, the disclosure of which isincorporated by reference in its entirety, discloses a designmethodology for an actuator body and a swirl nozzle (insert) so as tomaintain a small particle size using a compressed gas VOC-freepropellant for an air freshener product. What we have surprisingly foundis that certain ratios of parameters, including the diameter of theswirl chamber Ds, the diameter of the outlet orifice do, the length ofthe outlet orifice lo, the depth of the swirl chamber Ls, and the totalcross-sectional areas of the inlet ports Ap, can lead to remarkablyconsistent flow rates and remarkably consistent particle sizes whendispensing compressed gas products using the insert. In particular, whenthe insert is configured such that Ds/do is 3.0 to 3.5, lo/do is 0.4 to0.6, Ls/Ds is 0.3 to 1.0, and Ap/(Ds·do) is 0.3 to 0.9, surprisingly lowamount of decrease in the flow rate occurs as a compressed gas productis dispensed from a compressed gas system that uses the insert. Thesesame ratios also provide surprisingly low rates of increase in particlesize as a compressed gas product is dispensed from the container. Theeffect of these ratios will be demonstrated in the tests set forthbelow.

Without being limited by any theory, it is believed that if the ratiosof Ds/do, lo/do, Ls/Ds, and Ap/(Ds·do) are outside the ranges describedabove, the swirling and particle breakup of the product that occurs inthe swirl chamber changes more significantly as the product is dispensedfrom the container. As discussed above, unlike LPG in LPG systems, theamount of compressed gas propellant in a system is reduced as theproduct is dispensed. This aspect of a compressed gas system maycontribute to the decrease in flow rate and the increase in particlesize as the compressed gas product is dispensed. On the other hand,having the above-described ratios of parameters in the identified rangesmay act to negate some of the effects of the reduced amount ofcompressed gas on the flow rate and particle size.

As will be appreciated by those skilled in the art, a wide variety ofcompressed gas products can be used in systems according to theinvention. As non-limiting examples, such compressed gas products caninclude air fresheners, combination air and fabric fresheners,refreshers, deodorizers, sanitizers, disinfectants, soaps, insecticides,insect repellants, fertilizers, herbicides, fungicides, algaecides,pesticides, rodenticides, paints, deodorants, deodorants, body sprays,hair sprays, topical sprays, cleaners, polishes, and shoe or footwearspray products. Examples of specific compressed gas product formulationsthat can be used with apparatuses, systems, and methods according to theinvention are set forth in U.S. patent application Ser. No. 13/422,096,the disclosure of which is incorporated by reference in its entirety.Along these lines, one of ordinary skill in the art will appreciate thatproperties of such compressed gas products, including viscosity,density, and surface tension, can easily be adjusted to achieve desiredeffects. In example embodiments, the density of the compressed gasproduct is about 1.00 g/cm³, the surface tension is about 30 mN/m, andthe viscosity is about 1.0-1.6 cP.

The particular type of compressed gas that is used as the propellant insystems according to the invention can be selected based on convenience,cost, properties of the corresponding container, properties of theliquid product formulation, etc. Examples of known compressed gases thatcan be used in systems according to the invention include air, argon,nitrogen, nitrous oxide, inert gases, and carbon dioxide. Along with theparticular type of compressed gas, the amount of headspace provided bythe compressed gas can be adjusted or tailored as desired. As compressedgases do not significantly dissolve in the liquid portion of acompressed gas product, the amount of headspace is primarily a functionof the amount of compressed gas used in the container. In exampleembodiments of systems according to the invention, a headspace of 30 to40% is used. However, in alternative embodiments the headspace could belower than 30% or higher than 40%.

The container for use in systems of the invention may be a metalliccontainer, such as a steel or aluminum canister, or combinationsthereof. Alternatively, the container could be manufactured using anyplastic or resin. Example of such plastics or resins includepolyethylene terepthalate (PET), preferably clear PET, polycarbonate,polyacrylate, polyethylene naphthalate (PEN), a sandwhich layer plasticsuch as ethylene vinyl alcohol copolymer (EVOH) and PET, a copolyestersuch as is sold under the trademark TRITON™ by Eastman Chemical Companyof Kingsport, Tenn., or impact-modified acrylonitrile-methyl acrylatecopolymers such as are sold under the trademark BAREX® by Ineos Olefins& Polymers of League City, Tex. Of course, one of ordinary skill in theart will recognize that there are other materials that could also beused to manufacture the canister.

The container can also be adopted for the particular compressed gasformulation, as is described in the aforementioned U.S. patentapplication Ser. No. 13/422,096, or other alternative compressed gasformulations. As will be appreciated by those skilled in the art,containers used to provide compressed gas products are required by lawto be made in accordance with Department of Transportation (DOT) andInterstate Commerce Commission (ICC) regulations. These regulationsmandate certain dimensional, material, manufacture, wall thickness, andtesting requirements for a container to be charged to a given pressure.For example, a 2P rated container can be used if the internal pressureis from 140 to 160 psig at 130° F., and a 2Q rated container can be usedif the internal pressure is from 161 to 180 psig at 130° F. In general,the containers used in conjunction with the present invention can beadjusted to meet these regulations, and as such, be used to provide acompressed gas product at any given pressure in the container. Inparticular embodiments, however, systems of the invention arespecifically designed as 2Q and 2P rated containers. Example embodimentsof the invention include containers initially charged with up to 157psig at 70 ° F. of compressed gas product.

Insert Parameter and Container Pressure Testing

In order to determine the effect of the above-described parameters of aninsert on the flow rate and particle size of a dispensed compressed gasproduct, a series of tests was conducted with different inserts. Theparameters of the inserts varied, and the parameters are listed in Table1 below. In Table 1, the same abbreviations for the insert parametersare used as are described above. Specifically, the diameter of theoutlet orifice is labeled do, the diameter of the swirl chamber islabeled Ds, the length of the outlet orifice is labeled lo, the depth ofthe swirl chamber is labeled Ls, and the total cross-sectional area ofthe inlet ports to the swirl chamber is labeled Ap. The values of all ofthese parameters are given in inches, except for the cross-sectionalarea Ap, which is given in square inches. Table 1 further indicates thenumber of inlet ports “n” leading to the swirl chamber of each insert.

The flow rates indicated in Table 1 were determined by dischargingsystems including the inserts for sixty seconds. The flow rate wasmeasured using a stopwatch and a scale made by Mettler-Toledo ofColumbus, Ohio. All of the other parameters of the system, such as theconfiguration of the dispenser assembly and container, the size of thecontainers, the initial pressure in the containers, etc., were the samefor all of the inserts. Additionally, all of the tests were conducted atambient temperature (about 70° F.).

TABLE 1 Ap Flow Rate Insert do Ds Ds/do lo lo/do n Ls Ls/Ds Ap (Ds · do)(g/s) 1 0.014 0.046 3.30 0.007 0.50 4 0.010 0.22 0.0004 0.6184 1.40 20.014 0.046 3.30 0.011 0.79 4 0.008 0.17 0.0003 0.3958 1.15 3 0.0130.046 3.54 0.011 0.85 4 0.010 0.22 0.0004 0.6689 1.11 4 0.015 0.046 3.070.007 0.47 4 0.011 0.24 0.0005 0.7014 1.50 5 0.015 0.046 3.07 0.007 0.474 0.015 0.33 0.0006 0.8696 1.72 6 0.013 0.041 3.15 0.013 1.00 5 0.0080.20 0.0007 1.2758 1.56 7 0.015 0.031 2.07 0.011 0.73 5 0.015 0.480.0009 1.9355 1.79

As demonstrated by the data in Table 1, the parameters do, Ds, lo, Ls,and Ap function together synergistically to affect the flow ratedispensed through an insert. That is, while one of the parameters, suchas the diameter of the outlet orifice, might be directly related to theflow rate, the actual flow rate is a result of the combination of allthe parameters.

More importantly, we found from tests such as those shown in Table 1that the above-described specific ratios of Ds/do, lo/do, Ls/Ds, andAp/(Ds·do) lead to surprisingly consistent flow rates and particlesizes. Further tests demonstrating our findings with respect to theratio of parameters are described below.

Tests were also conducted to correlate the pressure of the containerhaving an insert according to the invention with the amount of productremaining in the container. The results of these tests are shown inTable 2.

TABLE 2 % of Full Target Fill Pressure Measurements (psig) ContainerWeight (g) Sample 1 Sample 2 Sample 3 Average 100 227 135 136 136 135.6± 0.5  90 204 116 116 117 116.3 ± 0.5  80 182 100 101 100 100.3 ± 0.5 66 150 86 87 87 86.6 ± 0.5 50 113 72 72 72 72.0 ± 0.0 33 75 61 62 6161.3 ± 0.5 13 30 51 52 51  51.3 ± 0.53 0 0 42 36 40 39.3 ± 3.0

As can be seen from the data in Table 2, the pressure in the containerof the system ranged from about 135 psig when the container wasinitially filled with the compressed gas product, to about 40 psig whenall of the compressed gas product had been dispensed from the container.These pressures can be directly correlated to the amount of productremaining in the container in the tests involving Insert A describedbelow.

Insert Parameter Comparison Testing

An insert A according to the invention was compared in the testsdiscussed below to the inserts B and C, which were provided oncompressed gas product dispensing systems that are sold in retailstores.

The insert A according to the invention was provided on a system thatincluded a dispenser assembly and associated container, as generallydescribed above. The container initially included 227 grams (about 8ounces) of an air freshening product, and nitrogen was used as the gaspropellant. The container was initially pressurized to about 135-138 psiwith the compressed gas product, and had 36% headspace. The parametersof insert A are shown in Table 3 below.

The insert B was part of a product available in retail stores. Thesystem with insert B included a container having 226 grams of an airfreshening product. Insert C was also part of a product available inretail stores. The system with insert C included a container having 275grounds of an air freshening product. The specific parameters forinserts B and C are shown in Table 3 below.

The same abbreviations and units of measure for the insert parametersare used in Table 3 as are used in Table 1 above.

TABLE 3 Ap Insert do Ds Ds/do lo lo/do n Ls Ls/Ds Ap (Ds · do) A 0.0150.046 3.07 0.007 0.47 4 0.015 0.32 0.00060 0.8696 B 0.013 0.053 4.070.010 0.77 4 0.010 0.19 0.00060 0.8708 C 0.014 0.038 2.71 0.015 1.07 30.010 0.26 0.00042 0.7894

It should be noted that some of the individual parameters of Insert Ashown in Table 3 are not significantly different from the parameters forInserts B and C. For example, the diameter do of the outlet orifice forInsert A is very close to the diameters do for Inserts B and C, and thediameter of the swirl chamber Ds of Insert A falls between the diametersDs for Inserts B and C. Some of the ratios of parameters for Insert A,however, such as Ds/do, lo/do, and Ls/Ds are significantly differentthan the ratios for Inserts B and C. As discussed above, it is believedthat configuring an insert with these ratios leads to a surprisinglyconsistent flow rate and surprisingly consistent particle size as thecompressed gas product is dispensed, and tests demonstrated suchconsistency in the dispensed product are discussed below.

Sixty Second Spray Comparisons

The flow rates dispensed from compressed gas systems using inserts A, B,and C were compared. In each case, three fully charged systems havingthe inserts were provided, and each of the systems was discharged forsixty seconds. The flow rate was determined using a stopwatch and ascale made by Mettler-Toledo of Columbus, Ohio. All of the tests wereconducted at ambient temperature (about 70° F.). The results of the flowrate tests are shown in Table 4.

TABLE 4 Sample Flow Rate (g/sec.) Number Insert A Insert B Insert C 11.85 1.48 1.18 2 1.85 1.45 1.35 3 1.84 1.43 1.39 Average 1.85 ± 0.0051.45 ± 0.02 1.30 ± 0.011

The results shown in Table 4 indicate that Insert A had a higher flowrate than did Inserts B and C.

The average particle size dispensed from Inserts A, B, and C wasdetermined in a sixty second dispensing test. In this test, the samplesfrom three fully charged systems with Insert A were dispensed and theparticle size was determined using a particle analyzer made by MalvernInstruments of Malvern, Worcestershire, UK. A mass median diameter (MMD)of particles in the samples was thereby obtained, with the MMDrepresenting a particle diameter that is larger than 50% of the sampledvolume. All of the tests were conducted at ambient temperature (about70° F.). The result of the test is shown in Table 5.

TABLE 5 Sample Particle Size (μm) Number Insert A Insert B Insert C 163.01 74.18 66.01 2 67.08 75.52 68.95 3 65.59 76.01 68.82 Average 65.23± 2.05 75.23 ± 0.9 67.86 ± 1.6

As can be seen from the results shown in Table 5, Insert A providedduring the sixty second dispensing test an average particle size ofabout 65 μm, while Inserts B and C provided average particle sizes ofabout 75 μm and 68 μm, respectively.

As discussed above, in the case of air fresheners a goal is to dispensea product with a flow rate and a particle size such that a sufficientamount of fragrance experience is achieved soon after the dispensing,while at the same time dispensing the product in a manner that providesfor longevity of the fragrance experience. In embodiments of the presentinvention, the combination of flow rate and particle size that werefound in the sixty second dispensing tests using Insert A are conduciveto both a favorable initial fragrance experience and a sustainedfragrance experience.

Ten Second Spray Comparisons

The flow rates and particle sizes in ten second sprays from systems thatincluded the Inserts A, B, and C were compared. In each case, threesystems having the inserts were provided, and the systems weredischarged for ten seconds. The flow rates and average particle sizes(MMD) were determined according to the methods described above. Thetests were then repeated when the containers had 66%, 33%, and 13% ofthe initial amount of product (by mass) remaining in the containers. Allof the tests were conducted at ambient temperature (about 70° F.).

The results of the tests are shown in Tables 6-9 below. Table 6 show theresults of the 10 second spray from 100% full containers. Tables 7, 8,and 9 show the results from 66%, 33%, and 13% full (by mass) containers,respectively.

TABLE 6 100% Full Containers Insert A Insert B Insert C Spray ParticleSpray Particle Spray Particle Sample Rate Size Rate Size Rate SizeNumber (g/s) (μm) (g/s) (μm) (g/s) (μm) 1 2.03 67.32 1.73 70.14 1.5861.69 2 2.04 65.69 1.68 70.22 1.65 60.43 3 2.04 61.61 1.74 70.61 1.5159.36 Average 2.036 ± 64.96 ± 1.72 ± 70.32 ± 1.58 ± 60.49 ± 0.01 3.00.03 0.25 0.07 1.16

TABLE 7 66% Full Containers Insert A Insert B Insert C Spray ParticleSpray Particle Spray Particle Sample Rate Size Rate Size Rate SizeNumber (g/s) (μm) (g/s) (μm) (g/s) (μm) 1 1.69 70.68 1.37 77.84 1.2270.64 2 1.68 69.25 1.34 79.04 1.32 67.11 3 1.66 75.85 1.35 82.18 1.1673.56 Average 1.67 ± 71.93 ± 1.35 ± 79.68 ± 1.23 ± 70.44 ± 0.01 3.470.01 2.24 0.08 3.23

TABLE 8 33% Full Containers Insert A Insert B Insert C Spray ParticleSpray Particle Spray Particle Sample Rate Size Rate Size Rate SizeNumber (g/s) (μm) (g/s) (μm) (g/s) (μm) 1 1.42 75.23 1.17 93.31 1.0081.89 2 1.44 78.38 1.13 95.57 1.11 79.71 3 1.42 75.67 1.15 98.91 0.9482.45 Average 1.43 ± 76.43 ± 1.15 ± 95.93 ± 1.02 ± 81.35 ± 0.01 1.700.02 2.82 0.08 1.45

TABLE 9 13% Full Containers Insert A Insert B Insert C Spray ParticleSpray Particle Spray Particle Sample Rate Size Rate Size Rate SizeNumber (g/s) (μm) (g/s) (μm) (g/s) (μm) 1 1.33 87.47 1.05 109.4 0.8991.12 2 1.35 80.13 1.06 117.5 0.96 89.46 3 1.31 87.47 1.01 107.2 0.8290.42 Average 1.33 ± 85.02 ± 1.04 ± 111.3 ± 0.89 ± 90.33 ± 0.02 4.240.03 5.25 0.07 0.83

As is evident from Tables 6-9, the flow rate of product dispensed usingInsert A remained much more constant than the flow rates of the productsdispensed using Inserts B and C. The flow rate of Insert A, which wasabout 2.0 g/s for the initial 10 second dispensing, dropped by 18% toabout 1.7 g/s when the amount of product remaining was 66% the originalamount of product. When 33% of the original amount of product remained,the flow rate had dropped 30% to about 1.4 g/s, and decreased by about35% to about 1.3 g/s when 13% of the original amount of product remainedin the container. In other words, the flow rate when the container was13% full of product was still about 65% that of the flow rate when thecontainer was full. On the other hand, the flow rates using Inserts Band C had decreased by about 40% and about 44%, respectively, when 13%of the initial amount of product remained in the containers of thesystems. Moreover, at every measured step, i.e., 66%, 33%, and 13%product remaining, the flow rate using Insert A decreased by a lowerpercentage than the flow rates decreased using Inserts B and C. Thus,Insert A provided a significantly more consistent flow rate as theproduct was discharged from the system.

As is also evident from Tables 6-9, the particle size dispensed withInsert A remained much more constant than the particle size dispensedwith Inserts B and C. The particle size using Insert A, which was about65 μm for the initial 10 second dispensing, increased by 11% to about 72μm when the amount of product remaining was 66% the original amount.When 33% of the original amount of product remained, the particle sizehad increased by about 18% to about 76 μm, and increased by about 31% toabout 85 μm when 13% of the original amount of product remained in thecontainer. On the other hand, the particle size using Inserts B and Chad increased by about 58% and about 49%, respectively, when 13% of theinitial amount of product remained in the containers of the systems.Moreover, at every measured step, i.e., 66%, 33%, and 13% productremaining, the particle size using Insert A increased by a lowerpercentage than the particle sizes increased using Inserts B and C.Thus, Insert A provided a significantly more consistent particle size asthe product was discharged from the system.

As discussed above, important aspects of a system of providing anaerosol product are consistent flow rate of product and consistentparticle size. While the flow rate dispensed using Insert A decreasedand the particle size increased, the relative amount of change in theseaspects of product performance was significantly less than what occurredin the commercially-available systems that included Inserts B and C.Based on a comparison of the parameters of the Inserts A, B, and C shownin Table 3, it is apparent that the above-identified ratios involvingthe diameter of the swirl chamber Ds, the diameter of the outlet orificedo, the length of the outlet orifice lo, and the depth of the swirlchamber Ls, are responsible for the surprisingly stable flow rates andstable particle sizes found when using Insert A. Indeed, these resultsare all the more surprising when considering that, as noted above, someof these parameters for Insert A were, in and of themselves, nearly thesame as the parameters found in Inserts B and C.

As discussed above, factors such as temperature, pressure in thecontainer, and properties of the product formulation, such as densityand surface tension, might influence the performance of a compressed gasproduct, including the flow rate and particle size of the dispensedproduct. The above results clearly demonstrate, however, that at ambienttemperature and over the pressure ranges tested, i.e., from about 150psig to about 45 psig, a relatively consistent flow rate and relativelyconsistent average particle size can be obtained by configuring thedispensing insert with the combination of parameters described above.Moreover, as one of ordinary skill in the art will readily appreciate,while the actually measured flow rate and particle size that aredispensed with a given insert might be changed by a change in thetemperature, pressure, product formulation, etc., the above-describedcombinations of parameters of the insert that are used to achieve therelatively constant flow rate and relatively constant particle size willremain the same.

Although this invention has been described in certain specific exemplaryembodiments, many additional modifications and variations would beapparent to those skilled in the art in light of this disclosure. It is,therefore, to be understood that this invention may be practicedotherwise than as specifically described. Thus, the exemplaryembodiments of the invention should be considered in all respects to beillustrative and not restrictive, and the scope of the invention to bedetermined by any claims supportable by this application and theequivalents thereof, rather than by the foregoing description.

INDUSTRIAL APPLICABILITY

The inventive apparatuses, systems, and methods described herein can beused to dispense a wide variety of commercial products, such as airfresheners, soaps, insecticides, paints, deodorants, disinfectants. Assuch, inventive apparatuses, systems, and methods described herein areapplicable in a wide variety of industries.

1. An insert for use with an assembly to dispense a compressed gasproduct from a container, the insert comprising: a swirl chamber havinga diameter Ds and a depth Ls; at least one inlet port opening to theswirl chamber; and an outlet orifice having a diameter do and a lengthlo, wherein the insert is configured such that: Ds/do is about 3.0 toabout 3.5, lo/do is about 0.4 to about 0.6; and Ls/Ds is about 0.3 toabout 1.0.
 2. A insert according to claim 1, wherein the at least oneinlet port has a cross-sectional area Ap, and the nozzle is configuredsuch that: Ap/(Ds·do) is about 0.3 to about 0.9.
 3. The nozzle accordingto claim 2, wherein the at least one inlet port includes four inletports each having equal cross-sectional areas such that the totalcross-sectional area Ap of the inlet ports is about 0.00060 in².
 4. Thenozzle according to claim 2, wherein Ds is about 0.046 in., do is about0.015 in., lo is about 0.007 in., Ls is about 0.015 in., and Ap is about0.0006 in.
 5. The nozzle according to claim 1, wherein the swirl chamberhas a square shape.
 6. The nozzle according to claim 1, wherein fourinlet ports are provided to the swirl chamber.
 7. A method of minimizinga change in flow rate of a compressed gas product and minimizing anincrease in particle size of the compressed gas product dispensed from acontainer through a dispenser assembly that includes an insert, theinsert having (i) a swirl chamber with a diameter Ds and a length Ls,(ii) at least one inlet port opening to the swirl chamber, the at leastone inlet port having a cross-sectional area Ap, and (iii) an outletorifice having a diameter do and a length lo, the method comprising:adjusting the ratio Ds/do to be in the range of about 3.0 to about 3.5;adjusting the ratio lo/do to be in the range of about 0.4 to about 0.6;adjusting the ratio Ls/Ds to be in the range of about 0.3 to about 1.0;and adjusting the ratio Ap/(Ds·do) to in the range of about 0.3 to about0.9.
 8. A method according to claim 7, wherein the at least one inletport has a cross-sectional area Ap, and the nozzle is configured suchthat: Ap/(Ds·do) is about 0.3 to about 0.9.
 9. The method according toclaim 8, wherein the at least one inlet port includes four inlet portseach having equal cross-sectional areas such that the totalcross-sectional area Ap of the inlet ports is about 0.00060 in².
 10. Themethod according to claim 8, wherein Ds is about 0.046 in., do is about0.015 in., lo is about 0.007 in., Ls is about 0.015 in., and Ap is about0.0006 in.
 11. The method according to claim 7, wherein the swirlchamber has a square shape.
 12. The method according to claim 7, whereinfour inlet ports are provided to the swirl chamber.
 13. A method ofminimizing a change in flow rate of a compressed gas product andminimizing an increase in particle size in the compressed gas productdispensed from a container through an insert provided to a dispenserassembly associated with the container, with the insert having (i) aswirl chamber with a diameter Ds and a length Ls, (ii) at least oneinlet port opening to the swirl chamber, the at least one inlet porthaving a cross-sectional area Ap, and (iii) an outlet orifice having adiameter do and a length lo, the method comprising: adjusting the ratioDs/do; adjusting the ratio lo/do; adjusting the ratio Ls/Ds; andadjusting the ratio Ap/(Ds·do), wherein a spray rate during an initialsixty second dispensing of the compressed gas product through the insertis at least about 1.7 g/s.
 14. A method according to claim 13, whereinthe at least one inlet port has a cross-sectional area Ap, and thenozzle is configured such that: Ap/(Ds·do) is about 0.3 to about 0.9.15. The method according to claim 13, wherein the at least one inletport includes four inlet ports each having equal cross-sectional areassuch that the total cross-sectional area Ap of the inlet ports is about0.00060 in².
 16. The method according to claim 15, wherein Ds is about0.046 in., do is about 0.015 in., lo is about 0.007 in., Ls is about0.015 in., and Ap is about 0.0006 in.
 17. The method according to claim13, wherein the swirl chamber has a square shape.
 18. The methodaccording to claim 13, wherein four inlet ports are provided to theswirl chamber.
 19. The method according to claim 13, wherein an averageparticle size during the sixty second dispensing is about 65 μm.
 20. Themethod according to claim 13, wherein the spray rate during the initialsixty second dispensing of is about 1.85 g/s.